Sheet manufacturing apparatus and sheet manufacturing method

ABSTRACT

A composite to be mixed with fibers for forming a sheet by heat includes a resin particle for bonding the fibers, and inorganic fine particles that coat at least a portion of a surface of the resin particle.

This application is a continuation application of U.S. patentapplication Ser. No. 14/984,100, filed on Dec. 30, 2015. Thisapplication claims priority to Japanese Patent Application No.2015-021829 filed on Feb. 6, 2015. The entire disclosures of U.S. patentapplication Ser. No. 14/984,1.00 and Japanese Patent Application No.2015-021829 are hereby expressly incorporated herein by reference.

BACKGROUND 1. Technical Field

The present invention relates to a sheet manufacturing apparatus and asheet manufacturing method.

2. Related Art

Depositing a fiber-like material and causing a bonding force between thedeposited fibers to obtain a sheet-like or film-like formed body hasbeen performed for a long time. Typical examples thereof includemanufacturing paper by pulp molding (paper-forming) using water. Even inpresent times, pulp molding is widely used as an example of a method ofmanufacturing paper. The paper manufactured by pulp molding generallyincludes a structure by cellulose fibers derived from wood or the likebeing entangled with one another, and being partially bonded to oneanother by a binder (paper strengthening agent (such as a starch pasteand a water-soluble resin)).

According to the pulp molding, it is possible for the fibers to bedeposited in a state where uniformity is favorable, and, in a case wherea paper strengthening agent is used in the bonding between fibers, it ispossible for the paper strengthening agent to be dispersed (distributed)in a state where the uniformity in the paper surface is good. However,because the pulp molding is a wet method, it is necessary to use largevolumes of water, and the necessity of dewatering and drying, or thelike, arises after forming the paper, and therefore the energy or timeconsumed is extremely large. It is necessary to suitably process thewater used as waste water. Accordingly, it is difficult to respond tomodern demands for energy savings, environmental protection, and thelike. The apparatuses used in pulp molding frequently need large scaleutilities such as water, power, and drainage facilities, and sizereductions are difficult. From this viewpoint, there is an expectationof methods, referred to as dry methods that use no or almost no water aspaper manufacturing methods in place of pulp molding.

For example, in the technology disclosed in JP-A-2011-099172, an attemptat bonding fibers to one another with a thermal fusion-bondable resin inair-laid non-woven fabric that includes a highly water absorbent resinis disclosed.

However, in the technology disclosed in JP-A-2011-099172, the thermalfusion-bondable resin has the properties of a powder, and there is adanger of detachment from between the fibers when air-laid. Paragraph[0013] in JP-A-2011-099172 discloses that when thermal fusion-bondablepowder is too small, the powder passes through the mesh conveyor (meshbelt) and it is difficult for the fibers to be bonded to one another.Accordingly, JP-A-2011-099172 describes that it is favorable to use athermal fusion bondable resin powder of the comparatively large particlediameter (20 mesh pass to 300 mesh on).

However, when the particle diameter of the resin is large, theuniformity of the distribution of the resin in the manufactured sheetmay be impaired. Accordingly, it is desirable that the particle diameterof the resin is smaller in order for the resin to be uniformly dispersedbetween the fibers.

In a case of forming a web by air-laying, suctioning is ordinarilyperformed from below the mesh belt. Thus, when the particle diameter ofthe resin is smaller than the size of the openings in the mesh belt, itis thought that the resin easily detaches from between the fibers duringweb formation. Therefore, even if the particle diameter of the resin isreduced, work is necessary to make the resin difficult to detach frombetween the fibers.

SUMMARY

An advantage of some aspects of the invention is to provide a sheetmanufacturing apparatus and a sheet manufacturing method that uses athermal fusion-bondable resin that is not easily detached from betweenfibers.

The invention can be realized in the following forms or applicationexamples.

According to an aspect of the invention, there is provided a sheetmanufacturing apparatus including a mixing unit configured to mix fibersand a composite in the atmosphere, and a forming unit configured todeposit and heat a mixture mixed by the mixing unit to form a sheet; inwhich the composite is resin particles with at least a portion of asurface covered with inorganic fine particles, and an absolute value ofan average charging amount of the composite is 40 μC/g or higher.

According to the sheet manufacturing apparatus of the applicationexample, because the composite that is resin particles with at least aportion of the surface is covered with the inorganic fine particles ismixed in air with fibers, the composite is more easily charged andattached to the fibers during mixing, and the composite is not easilydetached from the fibers during forming of the web. Since the compositeand the fibers are bonded (fusion bonded) in this state, it is possibleto manufacture a sheet with favorable strength.

In the sheet manufacturing apparatus according to the aspect of theinvention, the volumetric average particle diameter of the resinparticles may be 25 μm or less.

According to the sheet manufacturing apparatus, because the composite issmall on the order of 25 μm or less, the composite is easily mixed andeasily dispersed between the fibers. The composite particle is small andhas a light weight, and thus is not easily influenced by gravity and noteasily detached from the web or sheet.

In the sheet manufacturing apparatus according to the aspect of theinvention, the volumetric average particle diameter of the inorganicfine particles may be 40 μm or less.

When the average particle diameter of the inorganic fine particles is 40nm or less, it is possible for the charging amount of the composite tobe further increased.

In the sheet manufacturing apparatus of the aspect of the invention, thecomposite may not be divided into the resin and the inorganic fineparticles during mixing in the mixing unit.

According to such a sheet manufacturing apparatus, since not only arethe inorganic fine particles simply attached to the resin in a compositestate, but the composite is also integrated to an extent where the resinand the inorganic fine particles are not divided during mixing, droppingof the inorganic fine particles less easily occurs during mixing.

In the sheet manufacturing apparatus according to the aspect of theinvention, the forming unit may further include a discharging unitconfigured to discharge the mixture, a mesh belt configured toaccumulate the mixture, and a suction unit configured to suctions gasthat includes the mixture via the mesh belt.

By performing suction via the mesh belt, although the possibility of thecomposite detaching from the fibers increases, according to the sheetmanufacturing apparatus of the application example, it is possible tosuppress detachment of the composite from the fibers even when thesuction unit is included.

In the sheet manufacturing apparatus according to the aspect of theinvention, the content of the inorganic fine particles in the compositemay be 0.1% by weight or more to less than 4% by weight.

According to such a sheet manufacturing apparatus, even if the contentof the inorganic fine particles in the composite is reduced to 0.1% byweight or more to less than 4% by weight, it is possible to sufficientlyobtain the charging effect. Therefore, it is possible for the usageamount of the inorganic fine particles to be reduced.

In the sheet manufacturing apparatus according to the aspect of theinvention, the mixing unit may include a plurality of rotary unitshaving blades that rotate, and may mix the fibers and the composite bybeing passed through the rotary unit.

According to such a sheet manufacturing apparatus, the composite is moreeasily charged, and less easily detaches from the fibers by the fibersand the composite being passed through the rotary unit having bladesthat rotate.

According to another aspect of the invention, there is provided a sheetmanufacturing method including mixing the fibers and the composite, inwhich the resin and the inorganic fine particles are integrated, in air,and depositing, heating and forming a mixture in which the fibers andthe composite are mixed.

According to such a sheet manufacturing method, because the compositethat is resin particles covered with the inorganic fine particles ismixed in air with fibers, the composite is more easily charged andattached to the fibers during mixing, the composite is not easilydetached from the fibers during forming of the web and it is possible tomanufacture a sheet with favorable uniformity of strength or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described with reference to the accompanyingdrawings, wherein like numbers reference like elements.

FIG. 1 is a drawing schematically showing a sheet manufacturingapparatus according to an embodiment.

FIGS. 2A and 2B are schematic views of several examples ofcross-sections of the composite according to the embodiment.

FIG. 3 is a schematic view showing an example of a suction deviceaccording to an example.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Below, various embodiments of the invention will be described. Theembodiments described below are for describing examples of theinvention. The invention is not limited in any way by the followingembodiments, and includes various modifications carried out in a rangenot departing from the gist of the invention. Not all of theconfigurations explained below are indispensable configurations in theinvention.

1. Sheet Manufacturing Apparatus

The sheet manufacturing apparatus according to the embodiment includes amixing unit that mixes fibers and a composite in the atmosphere, aforming unit that deposits and heats a mixture mixed by the mixing unitto form a sheet; in which the composite is resin particles with at leasta portion of the surface covered by inorganic fine particles, and anabsolute value of an average charging amount of the composite is 40 μC/gor higher.

1.1. Configuration

First, an example of the sheet manufacturing apparatus according to theembodiment will be described with reference to the drawings. FIG. 1 is adrawing schematically showing a sheet manufacturing apparatus 100according to the embodiment.

The sheet manufacturing apparatus 100 is provided with a supplying unit10, a manufacturing unit 102, and a controller 140, as shown in FIG. 1.The manufacturing unit 102 manufactures a sheet. The manufacturing unit102 includes a crushing unit 12, a defibrating unit 20, a classifyingunit 30, a screening unit 40, a first web forming unit 45, a mixing unit50, a deposition unit 60, a second web forming unit 70, a sheet formingunit 80, and a cutting unit 90.

The supplying unit 10 supplies raw materials to the crushing unit 12.The supplying unit 10 is an automatic feeding unit for continuouslyfeeding the raw materials to the crushing unit 12. The raw materialssupplied by the supplying unit 10 include fibers such as recycled pulpand pulp sheets.

The crushing unit 12 cuts the raw material supplied by the supplyingunit 10 into small pieces in air. The shape and size of the small piecesis several cm squared. In the examples in the drawings, the crushingunit 12 includes a crushing blade 14, and it is possible for the fed rawmaterials to be cut by the crushing blade 14. A shredder is used as thecrushing unit 12. The raw material cut by the crushing unit 12 istransferred (transported) to the defibrating unit 20 via a pipe 2 oncereceived by a hopper 1.

The defibrating unit 20 defibrates the raw material cut by the crushingunit 12. Here, the wording “defibrates” refers to untangling the rawmaterial (material to be defibrated) in which a plurality of fibers arebonded into individual fibers. The defibrating unit 20 also has afunction of causing substances such as resin powder bonded to the rawmaterial, ink toner, or blur-preventing agent to be isolated from thefibers.

The material that passes through the defibrating unit 20 is referred toas a “defibrated material”. There are also cases where resin (resin forcausing a plurality of fibers to bond to one another) powder isolatedfrom the fibers when the fibers are untangled, colorants such as ink andtoner, and additives such as bleeding inhibitors and paper strengtheningagents are included in the “defibrated material” in addition to theuntangled defibrated material fibers. The shape of the untangleddefibrated material is string-like or ribbon-like. The untangleddefibrated material may be present in a state of not being entangledwith other untangled fibers (independent state) or may be present in astate being entangled with other untangled fibers to form a clump (astate of forming a so-called “lump”).

The defibrating unit 20 performs defibrating with a dry method in theatmosphere (in air). Specifically, an impeller mill is used as thedefibrating unit 20. The defibrating unit 20 has the function causing anairflow to be generated so as to suction the raw material and dischargethe defibrated material. In so doing, it is possible for the defibratingunit 20 to suction the raw material along with the airflow from anintroduction port 22, perform the defibration treatment, and transportthe raw material to the exit port 24 with the self generated airflow.The defibrated material that passes through the defibrating unit 20 istransferred to the classifying unit 30 via the pipe 3.

The classifying unit 30 classifies the defibrated material passingthrough the defibrating unit 20. Specifically, the classifying unit 30isolates and removes the defibrated material that is comparatively smallor has a low density (such as resin powder, colorant, and additive) fromthe defibrated material. In so doing, it is possible to increase theproportion accounted for by fibers that are comparatively large or havea high density from the defibrated material.

An airflow classifier is used as the classifying unit 30. The airflowclassifier generates a swirling airflow, and performs isolationaccording to differences in the centrifugal force received due to thesize and density of the classified materials, and it is possible toadjust the classification points through adjustment of the speed of theairflow and the centrifugal force. Specifically, a cyclone, an elbowjet, an eddy classifier, and the like are used as the classifying unit30. In particular, it is possible for the cyclone as shown in thedrawings to be favorably used as the classifying unit 30 because thestructure is simple.

The classifying unit 30 includes an introduction port 31, a body 32connected to the introduction port 31, a reverse conical portion 33positioned below the body 32 and contiguous with the body 32, a lowerexit port 34 provided in the lower center of the reverse conical portion33, and an upper exit port 35 provided in the upper center of the body32.

In the classifying unit 30, the airflow that carries along thedefibrated material introduced from the introduction port 31 is changedto a circular motion by the body 32. In so doing, centrifugal force isapplied to the introduced defibrated material, it is possible for theclassifying unit 30 to isolate the fibers (first classified material)with a higher density than the resin powder or the ink powder from thedefibrated material and the resin powder with a lower density than thefibers, colorant, additives or the like (second classified material)from the defibrated material. The first classified material isdischarged from the lower exit port 34, and introduced to the screeningunit 40 via the pipe 4. Meanwhile, the second classified material isdischarged from the upper exit port 35 to the receiving portion 36 viathe pipe 5.

The screening unit 40 introduces the first classified material(defibrated material defibrated by the defibrating unit 20) passingthrough the classifying unit 30 from the introduction port 42 andscreens the material according to fiber length. A sieve is used as thescreening unit 40. The screening unit 40 includes a mesh (filter,screen) and is able to divide fibers or particles (first screenedmaterial passing through the mesh) that are smaller than the size of theopenings of the mesh and included and fibers, non-defibrated pieces orlumps (second screened material not passing through the mesh) largerthan the size of the opening in the mesh included in the firstclassified material. For example, the first screened material istransferred to the mixing unit 50 via the pipe 7 once received by thehopper 6. The second screened material is returned to the defibratingunit 20 from the exit port 44 via the pipe 8. Specifically, thescreening unit 40 is a cylindrical sieve that is able to rotate by amotor. A metal mesh, an expanded metal in which a perforated metal plateis drawn, and a punched metal plate in which holes are formed in a metalplate by a pressing machine or the like are used as the mesh of thescreening unit 40.

The first web forming unit 45 transports the first screened materialpassing through the screening unit 40 to the mixing unit 50. The firstweb forming unit 45 includes a mesh belt 46, a tensioned roller 47, anda suction unit (suction mechanism) 48.

It is possible for the suction unit 48 to suction the first screenedmaterial dispersed in the air after passing through the opening (openingof the mesh) of the screening unit 40 on the mesh belt 46. The firstscreened material is deposited on the moving mesh belt 46 and forms theweb V. The specific configurations of the mesh belt 46, the tensionedroller 47, and the suction unit 48 are the same as the mesh belt 72, thetensioned roller 74, and the suction mechanism 76 of the second webforming unit 70, described later.

The web V is formed in a state of including large volumes of air andbeing softly swelled by passing through the screening unit 40 and thefirst web forming unit 45. The web V deposited on the mesh belt 46 isfed to the pipe 7 and transported to the mixing unit 50.

The mixing unit 50 mixes the first screened material (first screenedmaterial transported by the first web forming unit 45) passing throughthe screening unit 40 and the additive agent that includes a resin. Themixing unit 50 includes an additive agent supply unit 52 that suppliesthe additive agent, a pipe 54 that transports the screened material andthe additive, and a blower 56. In the examples in the drawings, theadditive agent is supplied from the additive agent supply unit 52 to thepipe 54 via the hopper 9. The pipe 54 is contiguous with the pipe 7.

An airflow is generated by the blower 56 in the mixing unit 50, and itis possible to transport the first screened material and the additiveagent while being mixed in the pipe 54. The mechanism by which the firstscreening material and the additive agent are mixed is not particularlylimited, and may be a mechanism that performs agitating with blades thatrotate at high speed, or may be a mechanism that uses the rotation of acontainer such as a V-type mixer.

A screw feeder as shown in FIG. 1, a disk feeder, not shown, or the likeis used as the additive agent supply unit 52. The additive agentsupplied from the additive agent supply unit 52 includes a resin forcausing the plurality of fibers to bond. At the point in time at whichthe resin is supplied, the plurality of fibers is not bonded. The resinis fused when passing through the sheet forming unit 80 and theplurality of fibers is bonded.

The resin supplied from the additive agent supply unit 52 is athermoplastic resin or a heat-curable resin, and is an AS resin, an ABSresin, polypropylene, polyethylene, polyvinyl chloride, polystyrene, anacrylic resin, a polyester resin, polyethylene terephthalate,polyphenylene ether, polybutylene terephthalate, nylon, polyamide,polycarbonate, polyacetal, polyphenylene sulfide, polyetherether ketone,or the like. These resins may be used independently or mixed, asappropriate. The additive agent supplied from the additive agent supplyunit 52 may be in the form of fibers, or may be in the form of a powder.

The additive agent supplied from the additive agent supply unit 52 mayinclude, according to the type of sheet manufactured, coloring agentsfor coloring the fibers, coagulation inhibitors for preventingaggregation of the fibers, and flame retardants for making the fibersand the like more difficult to burn, in addition to the resin that bondsthe fibers. The mixture (mixture of the first classified material andthe additive agent) passing through the mixing unit 50 is transferred tothe deposition unit 60 via the pipe 54.

The deposition unit 60 introduces the additive agent passing through themixing unit 50 from the introduction port 62, refines the entangleddefibrated material (fibers) and causes the defibrated material todescend while being disperse in air. The deposition unit 60 refines theentangled resin in a case where the resin of the additive agent suppliedfrom the additive agent supply unit 52 is in the form of a fiber. In sodoing, it is possible for the deposition unit 60 to cause the mixture tobe uniformly deposited on the second web forming unit 70.

A cylindrical sieve that rotates is used as the deposition unit 60. Thedeposition unit 60 includes a mesh, and causes the fibers of particles(passing through the mesh) included in the mixture passing through themixing unit 50 and smaller than the size of the mesh openings todescend. The configuration of the deposition unit 60 is that same as theconfiguration of the screening unit 40.

The “sieve” of the deposition unit 60 may have a function of screeningspecified target materials. That is, the wording “sieve” used as thedeposition unit 60 signifies a sieve provided with a mesh, and thedeposition unit 60 may cause all of the mixture introduced to thedeposition unit 60 to descend.

The second web forming unit 70 accumulates the passing-through materialpassing through deposition unit 60 and forms the web W. The second webforming unit 70 includes a mesh belt 72, a tensioned roller 74, and asuction mechanism 76.

The mesh belt 72 accumulates the passing-through material passingthrough the openings (openings of the mesh) of the deposition unit 60while moving. The mesh belt 72 has a configuration in which the meshbelt 72 is tensioned by the tensioned roller 74, and air that does noteasily pass through the passing-through material passes therethrough.The mesh belt 72 moves through the tensioned roller 74 rotating. The webW is formed on the mesh belt 72 by the passing-through material passingthrough the deposition unit 60 continuously accumulating while the meshbelt 72 continuously moves. The mesh belt 72 is made from a metal, aresin, a fabric, a non-woven fabric or the like.

The suction mechanism 76 is provided below (opposite side to thedeposition unit 60 side) the mesh belt 72. It is possible for thesuction mechanism 76 to cause a downward moving airflow (airflow fromthe deposition unit 60 to mesh belt 72) to be generated. It is possiblefor the mixture dispersed in the air by the deposition unit 60 to besuctioned onto the mesh belt 72 by the suction mechanism 76. In sodoing, it is possible for the discharge speed from the deposition unit60 to be increased. It is possible to form a down flow in the droppingpath of the mixture by the suction mechanism 76, and it is possible toavoid the defibrated material and the additive agent being entangledduring dropping.

As above, the web W is formed in a state of including large volumes ofair and being softly swelled by passing through the deposition unit 60and the second web forming unit 70 (web forming step). The web Wdeposited on the mesh belt 72 is transported to the sheet forming unit80.

In the examples in the drawings, a moisture-adjusting unit 78 thatadjusts the moisture of the web W is provided. It is possible for themoisture-adjusting unit 78 to add water or water vapor to the web W andregulate the ratio of the web W to the water.

The sheet forming unit 80 forms the sheet S by heating the web Wdeposited on the mesh belt 72. In the sheet forming unit 80, it ispossible for the plurality of fibers in the mixture to be bonded to oneanother via the additive (resin) by applying heat to the mixture of thedefibrated material and the additive agent mixed into the web W.

A heating roller (heater roller), a hot press molding machine, a hotplate, a hot air blower, an infrared heating device, or a flash fixingdevice is used as the sheet forming unit 80. In the examples in thedrawings, the sheet forming unit 80 is provided with a first bondingunit 82 and a second bonding unit 84, and the bonding units 82 and 84are each provided with a pair of heating rollers 86. It is possible toform the sheet S while continuously transporting the web W byconfiguring the bonding unit 82 and 84 as heating rollers 86, comparedto a case of configuring the bonding units 82 and 84 as a plate-likepress device (plate press device). The number of heating rollers 86 isnot particularly limited.

The cutting unit 90 cut the sheet S formed by the sheet forming unit 80.In the examples in the drawings, the cutting unit 90 includes a firstcutting unit 92 that cut the sheet S in a direction that intersects thetransport direction of the sheet S and a second cutting unit 94 thatcuts the sheet S in a direction parallel to the transport direction. Thesecond cutting unit 94 cuts the sheet S passing through the firstcutting unit 92.

As above, a cut-form sheet S with a predetermined size is formed. Thecut-form sheet S that is cut is discharged to the discharge unit 96.

1.2. Fiber

In the sheet manufacturing apparatus 100 of the embodiment, the rawmaterial is not particularly limited, and it is possible for a widerange of fiber materials to be used. Examples of the fibers includenatural fibers (animal or plant fibers) and chemical fibers (organic,inorganic or organic-inorganic composite fibers), and more specifically,examples include fibers made from cellulose, silk, wool, cotton, hemp,kenaf, flax, Ramie, jute, manila hemp, sisal hemp, softwood, andhardwood, and fibers made from rayon, lyocell, cupra, vinylon, acrylic,nylon, aramid, polyester, polyethylene, polypropylene, polyurethane,polyimide, carbon, glass, and metal and these may be used independentlyor mixed, as appropriate, or may be used as a regenerated fiber on whichpurification or the like is performed. Although examples of the rawmaterial include recycled paper and recycled cloth, at least one ofthese fibers may be included. The fiber may be dried or may be containedor be impregnated with a liquid such as water or an organic solvent.Various surface treatments may be performed. The material of the fibersmay be a pure material, or may be a material that includes variouscomponents such as impurities, additives and other components.

In this way, although the sheet manufacturing apparatus 100 of theembodiment can use various types of raw material, among these, arecycled paper, pulp sheet or the like that includes cellulose fibershas a more remarkable effect of improve the attachment of the compositeand the fibers due to the fiber, described later, than a case of otherfibers, because cellulose has a comparatively high hydrophilicity and isless easily charged.

When the fibers used in the embodiment are made one independent fiber,the average diameter (in a case where the cross-section is not a circle(diameter of a circle when a circle having the greatest length from thelengths in a direction perpendicular to the length direction orequivalent to the area of the cross-section (equivalent circlediameter)) thereof is 1 μm or more to 1000 μm or less, 2 μm or more to500 μm or less is preferable, and 3 μm or more to 200 μm or less is morepreferable.

Although the length of the fibers used by the sheet manufacturingapparatus 100 of the embodiment is not particularly limited, in oneindependent fiber, the length along the length direction of the fiber is1 μm or more to 5 mm or less, 2 μm or more to 3 mm or less ispreferable, and 3 μm or more to 2 mm or less is more preferable. In acase where the length of the fibers is short, although the strength ofthe sheets may be insufficient because the fibers do not easily bondwith the composite, it is possible to obtain a sufficiently strong sheetas long as the length is within the above ranges.

The average length of the fibers, as the length-length-weighted meanfiber length, is 20 μm or more to 3600 μm or less, 200 μm or more to2700 μm or less is preferable, and 300 μm or more to 2300 μm or less ismore preferable. The length of the fibers may have variations(distribution), and in a case where a normal distribution in adistribution obtained with an n of 100 or more is assumed, the δ for thelength of one independent fiber may be 1 μm or more to 1100 μm or less,preferable 1 μm or more to 900 μm or less, and more preferably 1 μm ormore to 600 μm or less.

It is possible to measure the thickness and length of the fibers withvarious optical microscopes, scanning electron microscopes (SEM),transmission electron microscopes, fiber testers, or the like. In a caseof microscopic observation, cross-sectional observation and observationin a state where both ends of the one independent fiber are stretched soas to not be cut away, as necessary, can be performed by carrying outpretreatment, as appropriate, on the observation sample, as necessary.

In the sheet manufacturing apparatus 100 of the embodiment, the fibrousraw material is defibrated by the defibrating unit 20, and transportedto the mixing unit 50 as the first screened material passing through theclassifying unit 30 and the screening unit 40. The classifying unit 30may be omitted in cases where the function (removal of resin powder andink powder from the defibrated material) of the classifying unit 30 withrespect to web V are fulfilled by the mesh belt 46 of the screening unit40 and the suction unit (suction mechanism) 48. In this case, thedefibrated material defibrated by the defibrating unit 20 is introducedto the screening unit 40.

1.3. Composite

The additive agent supplied from the additive agent supply unit 52includes a resin for causing the plurality of fibers to bond. At thepoint in time at which the resin is supplied, the plurality of fibers isnot bonded. The resin is fused when passing through the sheet formingunit 80 and the plurality of fibers is bonded.

In the embodiment, the additive agent supplied from the additive agentsupply unit 52 is a composite (particles) in which at least a portion ofthe surface of the resin particles is covered by inorganic fineparticles. The composite may be used independently or mixed with anothersubstance, as appropriate.

The composite of the embodiment receives a frictional charging actionwhen supplied from the additive agent supply unit 52 and passes throughthe mixing unit 50 and the deposition unit 60. The charged composite isattached (electrostatically adsorbed) to the fibers even in a statewhere attached to the fibers and deposited with on the mesh belt 72along with the fibers, to form the web W.

The absolute value of the average charging amount of the composite ofthe embodiment is 40 μC/g or higher. The absolute value of the averagecharging amount of the composite is preferably 60 μC/g or more, morepreferably 70 μC/g or more, still more preferably 80 μC/g or more, andparticularly preferably 85 μC/g or more because the higher the valuebecomes, the more it is possible for the composite to be strongly ormore frequently attached to the fibers.

It is possible for the charging amount of the composite to be measuredwhile the composite is frictionally charged. It is possible to performthe measurement of the charging amount by agitating (mixing) a powder,referred to as a standard carrier, and the composite in air, andmeasuring the charging amount of the powder. It is possible to use astandard carrier for a positive polarity toner or for a negativepolarity toner that is a spherical carrier in which the ferrite core issurface treated available (standard carrier for positive polarity ofnegative polarity toner, available as “P-01” or “N-01”) from the ImagingSociety of Japan, a ferrite carrier available from Powdertech Co., Ltd.or the like as the standard carrier.

More specifically, it is possible to obtain the absolute value of theaverage charging amount of the composite as shown next. A mixed powderwith 80% by weight of the carrier and 20% by weight of the composite isfed into an acrylic container, the container is rotated for 60 secondsat 100 rpm while being mounted to a ball mill table, and the carrier andthe composite (powder) are mixed. It is possible to determine theabsolute value [|μC/g|] of the average charging amount for the mixturein which the composite and the carrier are mixed by measuring with acompact draw-off charge measurement device (for example, a Model 210HS-2, manufactured by TREK Japan KK).

By the absolute value of the average charging amount of the compositebeing 40 μC/g or higher, it is possible for the charged composite to beattached (electrostatically adsorbed) to the fibers even in a statewhere attached to the fibers and deposited on the mesh belt 72 alongwith the fibers, to form a web W. Such a composite of the embodiment isrealized through the structure, materials, and the like as describedbelow in the next items.

It is preferable that the particle diameter of the composite particles(volumetric average particle diameter) is 50 μm or less, 30 μm or lessis more preferable, 25 μm or less is still more preferable, and 20 μm orless is particularly preferable. When the average particle diameter issmall, it is possible to suppress detachment of from the fibers due tothe weight of the particles themselves because the force of gravityacting on the composite is small, and because the air resistance is low,it is possible to suppress separation from between the fibers due to theairflow (wind) arising due to the suction mechanism 76 or the like andseparation due to mechanical vibration. If within the above particlediameter range, it is possible for the composite to be made sufficientlydifficult to detach from the fibers by an average charging amount of 40μC/g or higher.

Although the opening size of the mesh belt 72 can be set, asappropriate, because the composite attaches to the fibers, passingthrough the mesh belt 72 is suppressed even in a case where the particlediameter of the composite is smaller than the opening size (size of holethat matter passes through) of the mesh belt 72. That is, the compositeof the embodiment obtains a more remarkable effect in a case where theparticle diameter of the composite is smaller than the opening size ofthe mesh belt 72.

The lower limit of the average particle diameter of the compositeparticles is not particularly limited, for example, is 10 μm, and isarbitrary within a range able to be pulverized by a method of crushingor the like. The average particle diameter of the composite particle mayhave a distribution, and, as long as the resin and the inorganic fineparticles are integrated, it is possible to obtain the effect ofsuppressing detachment from between the above-described fibers.

It is possible to measure the average particle diameter of the compositeparticles using a particle size distribution analyzer in which themeasurement principle is the laser diffraction scattering method. Aparticle size distribution analyzer in which the measurement principleis dynamic light scattering (for example, the “Microtrac UPA”,manufactured by Nikkiso Co., Ltd.) is an example of the particlecounter.

The composite may contain other components. Examples of the othercomponents include organic solvents, surfactants, preservative andfungicide agents, antioxidants, ultraviolet absorbing agents, and oxygenabsorbing agents.

1.3.1. Structure of Composite

The composite is in a state in which inorganic fine particles cover atleast a portion of the surface of the resin particles, and the resinparticles or inorganic fine particles from the composite are in a stateof not easily breaking apart (not easily divided) in either or both ofthe sheet manufacturing apparatus 100 and in the web W or the sheet S.That is, the state in which inorganic fine particles cover at least aportion of the surface of the resin particles indicates at least onestate of a state in which the resin and the inorganic fine particles arekneaded, a state in which inorganic fine particles are attached orbonded to the surface of the resin particles, a state in which theinorganic fine particles are structurally (mechanically) fixed to thesurface of the resin particles, and a state in which the resin particlesand the inorganic fine particles are aggregated due to electrostaticforce, Van der Waal's forces or the like. The state in which inorganicfine particles cover at least a portion of the surface of the resinparticles may also be a state in which the inorganic fine particles areencapsulated by the resin particles or a state in which the inorganicfine particles are attached to the resin. Furthermore, these states mayalso be present at the same time. In the specification, the state inwhich inorganic fine particles cover at least a portion of the surfaceof the resin particles may be a state in which the resin particles andthe inorganic fine particles are integrally included.

FIG. 2 schematically shows several states of cross-sections of thecomposite in which the resin and the inorganic fine particles areintegrally included. Examples of the specific aspects of the compositein which the resin and the inorganic fine particles are integrallyincluded include, as shown in FIG. 2A, a composite co in which theinorganic fine particles in are kneaded into the resin re and dispersedand at least a portion of the inorganic fine particles are exposed inthe surface of the composite co.

As shown in FIG. 2B, the inorganic fine particles in may be arranged soas to cover the surface of the resin re. That is, examples of thespecific aspect of the composite in which the resin and the inorganicfine particles are integrally included, as shown in FIG. 2B, include acomposite co in which the inorganic fine particles in are embedded,bonded to and/or attached to the surface of the resin re. The bondingand or attachment of both of the component in the example may be basedon electrostatic forces, Van der Waal's forces, or the like.

In the structure of the composite co shown in FIGS. 2A and 2B, althoughthe inorganic fine particles in cover a portion of the surface of theparticles of the resin re, the inorganic fine particles in may cover theentire surface of the particles of the resin re, or may cover thesurface of the particles of the resin re in multiple layers. A structuremay be used in which the structure shown in FIG. 2A and the structureshown in FIG. 2B are combined.

In the examples in FIGS. 2A and 2B, although either of the externalshape of the composite and the external shape of the inorganic fineparticles are schematically shown as close to spherical, the externalshape of the composite and the inorganic fine particles is notparticularly limited, and may be a shape such as disk-shaped, needleshaped, and an irregular shape. However, it is more preferable that theshape of the composite approach spherical as much as possible because ofthe ease of being arranged between the fibers in the mixing unit 50.

The composite with any of the structures shown in FIGS. 2A and 2B isalso not easily divided into the resin and the inorganic fine particleswhen mixed in the mixing unit 50. In the present application, in a casewhere the resin and the inorganic fine particles are not divided in thecomposite, although it is desirable to be completely undivided withrespect to the number of composite particle of the powder overall, inpractice, achieving a state of being completely undivided is difficult.Therefore, the undivided state indicates a state in which the 70% ormore of the composite particle are not divided from the resin and theinorganic fine particles when averages with respect to number ofcomposite particles in the powder overall.

It is possible to verify the structure of the composite co as shown inFIGS. 2A and 2B through various means, such as any structural analysismethod such as an electron microscope. It is possible to evaluatewhether or not the inorganic fine particles are coated by the resinparticles by measuring the angle of repose. It this possible to measurethe angle of repose in compliance with the method of “AluminaPowder—Part 2: Determination of Physical Properties—2: Angle of repose”in JIS R 9301-2-2:1999. With respect to the resin particles not coatedby the inorganic fine particles, it is possible to verify that the angleof repose is small in a composite coated by the inorganic fineparticles.

1.3.2. Function of Composite

Although several aspects of the composite in which the resin and theinorganic fine particles are integrally included are given as examples,even in any of the aspects, the resin and the inorganic fine particlesare not easily isolated, and the composite adsorbed on the fibers is noteasily detached when receiving various treatments in the sheetmanufacturing apparatus 100 or when the web W or the sheet S is formed.

The inorganic fine particles have the function of improving the chargingamount of the resin particles (composite) in a case of being arranged onthe surface of the resin particles compared to a case where theinorganic fine particles are not present. Although various inorganicfine particles can be used, in the sheet manufacturing apparatus 100 ofthe embodiment, it is preferable to use a type (may be coated (covered)or the like) arranged in the surface of the composite because little tono water is used.

The inorganic fine particles cause an adsorptive force (adhesive force)to arise between the composite and the fibers by increasing the chargingproperties of the composite. Therefore, when deposited as a web W on themesh belt 72 of the second web forming unit 70 of the sheetmanufacturing apparatus 100, it is possible to make the composite lesseasily detach from the fibers. In so doing, it is possible to make themechanical strength of the sheet S manufactured by the sheetmanufacturing apparatus 100 a predetermined strength. That is, since thecomposite of the embodiment has a sufficient adhesive force(electrostatic bonding force) to the fibers when arranged between thefibers, the composite is not easily detached from the fibers. It isthought the cause for obtaining such an effect is because there is anaction in which a static electricity is generated by friction and thecomposite (resin) is caused to bond to the fibers, due to being moreeasily frictionally charged and the composite being mixed with thefibers in the atmosphere in the mixing unit 50 by the inorganic fineparticles being arranged in the surface of the resin particles.

1.3.3. Material of Composite

Although already described, examples of the type of the resin (componentof the resin particles) that is a component of the composite include athermoplastic resin or a heat-curable resin, and is an AS resin, an ABSresin, polypropylene, polyethylene, polyvinyl chloride, polystyrene, anacrylic resin, a polyester resin, polyethylene terephthalate,polyphenylene ether, polybutylene terephthalate, nylon, polyamide,polycarbonate, polyacetal, polyphenylene sulfide, polyetherether ketone,or the like. These resins may be used independently or mixed, asappropriate.

More specifically, the type of resin (component of the resin particles)that is a component of the composite may be either a natural resin or asynthetic resin, and may be either a thermoplastic resin or aheat-curable resin. In the sheet manufacturing apparatus 100 of theembodiment, the resin that configures the composite is preferably asolid at room temperature, and is preferably a thermoplastic resin inconsideration of bonding the resin due to heat in the sheet forming unit80.

Examples of the natural resin include rosin, dammar, mastic, copal,amber, shellac, dragon's blood palm resin, sandarac, and colophony, andthese resins may be independent or mixed, as appropriate, and may bemodified as appropriate.

Examples of the heat-curable resin from the synthetic resins includeheat-curable resins such as phenol resins, epoxy resins, melamineresins, urea resins, unsaturated polyester resins, allkyd resins,polyurethane, and heat-curable polyimide resins.

Examples of the thermoplastic resin from the synthetic resins include ASresins, ABS resins, polypropylene, polyethylene, polyvinyl chloride,polystyrene, acrylic resins, polyester resins, polyethyleneterephthalate, polyphenylene ether, polybutylene terephthalate, nylon,polyamide, polycarbonate, polyacetal, polyphenylene sulfide, andpolyetherether ketone.

Copolymerization or modification may be performed, and examples of suchsystems of resin include styrene resins, acrylic resins, styrene-acryliccopolymer resins, olefin based, polyvinyl chloride resins, polyesterresins, polyamide resins, polyurethane resins, polyvinyl alcohol resins,vinyl ether resins, N-vinyl resins, and styrene-butadiene resins.

Meanwhile, examples of the inorganic fine particles include fineparticles formed from inorganic materials, and it is possible for anextremely superior charging effect to be obtained by arranging these inthe surface of the resin particles (composite).

Specific examples of the material of the inorganic fine particlesinclude silica (silicon oxide), titanium oxide, aluminum oxide, zincoxide, cerium oxide, magnesium oxide, zirconium oxide, strontiumtitanate, barium titanate, and calcium carbonate. The inorganic fineparticles arranged in the surface of the resin particles may be a singletype or may be a plurality of types.

Although not particularly limited, the volumetric average (primary)particle diameter (volume average particle diameter) of the inorganicfine particles is 1 nm or more to 100 nm or less, preferably 2 nm ormore to 80 nm or less, more preferably 5 nm or more to 50 nm or less,and still more preferably 10 nm or more to 40 nm or less. Although theinorganic fine particles being primary particles is normal in light ofbeing close to the category of so-called nanoparticles, and the particlediameter being small, a plurality of primary particles may be bonded toform a higher order particle. The inorganic fine particles of theembodiment have a small particle diameter, the proportion of the surfacearea per weight is larger, and the area when frictionally chargedaccordingly is also large. Therefore, it is possible for the particlediameter of the inorganic fine particles to obtain a favorable chargingeffect if within the above ranges. If the particle diameter of theinorganic fine particles is within the above ranges, it is possible forthe surface of the composite to be well coated, and also on this point,it is possible to stably contribute a sufficient charging effect.

It is possible to measure the average (primary) particle diameter of theinorganic fine particles according to an established method from therelationship between the specific surface area and the density obtainedby a BET method or the like.

If the content of the inorganic fine particles in the composite is 0.01%by weight or more to 10% by weight or less to 100% by weight of thecomposite, it is possible to obtain the above effects, and from theviewpoint of further increasing the effect and/or effectively using theinorganic fine particles (when there are too many inorganic fineparticles, even if the addition amount is increased, the charging amountdoes not easily increase) or the like, 0.05% by weight or more to 5% byweight or less to 100% by weight of the composite is preferable, 0.1% byweight or more to 4% by weight or less is more preferable, and 0.1% byweight or more to 3% by weight or less is still more preferable.

The method of arranging (coating) the inorganic fine particles in thesurface of the composite is not particularly limited, and the inorganicfine particles may be arranged along with the resin when forming thecomposite by melt-kneading or the like as described above. However, ifdone in this way, because the inorganic fine particles are largelyarranged inside the composite, the charging amount with respect to theaddition amount of the inorganic fine particles is reduced. It is morepreferable that the inorganic fine particles are arranged as much aspossible in the surface of the composite based on the charge generatingmechanism. Although examples of the form for arranging the inorganicfine particles in the surface of the composite include coating andcovering, the entire surface of the composite is not necessarily coated.Although the coverage ratio may exceed 100%, when reaching approximately300% or more, because there are cases where the action of bonding thecomposite and the fibers is impeded, an appropriate coverage ratio isselected according to the situation.

Although various methods are considered as the method of arranging theinorganic fine particles in the surface of the composite, although it ispossible to exhibit the effect by simply mixing together both and beingattached to the surface only by electrostatic force or Van der Waal'sforces, the concern of dropping off remains. Therefore, a method offeeding and uniformly mixing the composite and the inorganic fineparticles in a mixer that rotates at high speed is preferable. It ispossible to use a known device as such a device, and it is possible toperform mixing using an FM mixer, a Henschel mixer, a super mixer, orthe like. It is possible to arrange the particles of the inorganic fineparticles in the surface of the composite by such a method. There arecases where at least a portion of the inorganic fine particles arrangedby such a method are arranged in a state of biting into or a state ofbeing embedded into the surface of the composite, and it is possible tomake the inorganic fine particles more difficult to detach from thecomposite, and it is possible to stably exhibit the charging effect.When such a method is used, it is possible to easily realize theabove-described arrangement in a system included little to no watercontent. Even if inorganic fine particles that do not bite into thecomposite are present, it is possible for such an effect to besufficiently obtained. It is possible for the states in which theinorganic fine particles bite into or are embedded in the surface of thecomposite to be verified by various electron microscopes.

If the proportion coved by the inorganic fine particles in the compositesurface (area ratio: in the specification, may be referred to as thecoverage ratio) is 20% or more to 100% or less, it is possible to obtaina sufficient charging effect. It is possible to adjust the coverageratio by incorporating in a device such as an FM mixer. If the specificsurface area of the inorganic fine particles and the composite is known,it is possible to perform regulation by the weight (mass) of eachcomponent when incorporated. It is possible to measure the coverageratio with various electron microscopes. In a case where the inorganicfine particles are arranged in a form of being not easily detached fromthe composite, it is possible for the inorganic fine particles to beintegrally included in the composite.

The inorganic fine particles may be subjected to surface modification.Specifically, the surface of the inorganic fine particles may bemodified by chemically treating the surfaces thereof with a silanecompound and these may be used. Examples of such a silane compoundinclude alkyl silanes, such as trimethyl silane, dimethyl silane,triethyl silane, triisopropyl silane, and triisobutyl silane, and silanecoupling agents such as vinyltrimethoxy silane and vinyltriethoxysilane.

Because the composite includes inorganic fine particles, the compositeeasily electrostatically attaches to the fibers, and it is possible tomake dropping from the fibers and dropping from the web and sheet lesseasily arise. It is possible to extremely favorably mix together thecomposite and the fibers due to the agitation of the airflow or mixer.Examples of reasons therefor include a tendency for the composite tobecome easier to charge with static electricity in a case whereinorganic fine particles are arranged in the surface of the composite,and the composite becomes easier to attach to the fibers due to thestatic electricity. The composite attached to the fibers by to thestatic electricity becomes less easily detached from the fibers even incases where a mechanical impact or the like occurs. Therefore, mixing isquickly performed and dropping off sufficiently suppressed without usinga special unit other than for mixing the fibers and the composite.Attachment of the composite to the fibers after mixing is stabilized, nodetachment phenomenon is observed in the composite.

It is thought that the composite particles become more strongly attachedto the fibers by the electrostatic force than in a case of independentresin particles. Even in a case where the resin particles include apigment, it is found that the effect of the inorganic fine particles isnot impeded. Although it is ordinarily difficult for static electricityto accumulate when the moisture is high, the adhesive force of thecomposite to the fibers is improved by the presence of the inorganicfine particles even if some measure of water content is included in acase where the fibers are cellulose.

1.3.4. Other Components

Although it has been described that coloring agents for coloring fibers,or flame retardants for making fibers or the like more difficult to burnmay be included in the composite, in cases where at least one type ofthese is included, it is possible for these effects to be more easilyobtained by blending these into the resin by melt-kneading. It ispossible to blend the inorganic fine particles by mixing the resinpowder and the inorganic fine particle powder with a high speed mixer orthe like after forming such as resin powder.

Although the above-described fibers and composite are mixed together inthe mixing unit 50, it is possible for the mixing ratio thereof to beregulated, as appropriate, according to the strength, usage, or the likeof the manufactured sheet S. If the manufactured sheet S is for a workusage, such as copy paper, the proportion of the composite to the fibersis 5% by weight or more to 70% by weight or less, and from theviewpoints of obtaining favorable mixing in the mixing unit 50 andmaking the composite more difficult to detach due to gravity in a casewhere the mixture is formed in a sheet-shape, 5% by weight or more to50% by weight of less is preferable.

1.4. Mixing Unit

The mixing unit 50 provided in the sheet manufacturing apparatus 100 ofthe embodiment has a function of causing the fibers and the composite tobe mixed together. At least the fibers and the composite are mixedtogether in the mixing unit 50. In the mixing unit 50, components otherthan the fibers and the composite may be mixed together. The wording“the fibers and the composite are mixed together” is defined as thecomposite being positioned between the fibers in a space (system) with afixed volume.

The process of mixing together in the mixing unit 50 of the embodimentis a method (dry-type) in which the fibers and the composite areintroduced into the airflow and diffused together in the airflow, and isa fluid dynamic mixing process. The wording “dry-type” in the mixingrefers to the state of being mixed together in air rather than in water.That is, the mixing unit 50 may function in the drying state, or mayfunction in a state where a liquid present as an impurity or anintentionally added liquid is present. In the case of intentionallyadding the liquid, it is preferable for the liquid to be added to anextent that the energy and time for removing the liquid through heat orthe like do not increase excessively in later processes. In the method,this is more preferable because the airflow in the pipe 54 or the likebeing turbulent make the mixing together efficient.

The processing capacity of the mixing unit 50 is not particularlylimited as long as it is able to cause the fibers (fibrous material) andcomposite to mix together, and it is possible to regulate the design, asappropriate, according to the manufacturing capacity (throughput) of thesheet manufacturing apparatus 100. It is possible for the regulation ofthe processing capacity of the mixing unit 50 to be performed by theflow rate of the gas for transferring the fibers and the composite inthe pipe 54, the introduction rage of the material, and the transferrate or the like being changed.

The mixture mixed together by the mixing unit 50 may be further mixed byanother configuration such as a sheet forming unit. In the example inFIG. 1, although the mixing unit 50 includes a blower 56 provided in thepipe 54, a further blower, not shown, may be included.

The blower is a mechanism in which the fibers and the composite aremixed, and includes a rotary unit having blades that rotate. By theblades rotating, either or both of the fibers and the composite arerubbed by the blades or impact the blades. By the blades rotating, anyor all of the fibers and the fibers, the fibers and the composite andthe composite and the composite impact each other and rub against oneanother according to the airflow formed by the blades.

It is thought that due to such impact or rubbing, at least the compositeis charged (charged with static electricity), and an adhesive force(electrostatic force) for attaching the composite to the fibers isgenerated. The strength of such an adhesive force depends on theproperties of the fibers and the composite and the structure (shape andthe like of the rotating blades) of the blower. Even in cases where oneblower 56 is provided as shown in FIG. 1, although it is possible toobtain a sufficient adhesive force, there are cases where it is possibleto obtain a stronger adhesive force by further providing another bloweron the downstream side of the additive agent supply unit 52. Theincreasing number of blowers is not particularly limited. In a case ofproviding a plurality of blowers, the main functions of the blowers maybe divided such as providing a blower with a strong air blowing force, ablower with a larger agitation force (capability caused by beingcharged) or the like. In this way, there are cases where it is possiblefor adhesive force of the composite to the fibers to be furtherincreased, and it is possible for detachment of the composite frombetween the fibers to be further suppressed when forming the web W.

1.5. Actions and Effects

For the sheet manufacturing apparatus 100 of the embodiment, because thecomposite mixed with the fibers in the mixing unit 50 has at least aportion of the surface of the resin particles coated by the inorganicfine particles, the composite is not easily detached from between thefibers when the web is formed. Since the composite and the fibers arebonded in the sheet forming unit 80, it is possible for thedispersibility of the resin to be favorable, and to manufacture a sheetwith favorable uniformity of strength and the like.

The composite used in the sheet manufacturing apparatus 100 of theembodiment has a much superior adhesive force with the fibers. By theinorganic fine particles being integrally added to the resin, thecomposite particles are easily charged with static electricity, theelectric charging amount as a result increases, and the adhesive forceto the fibers is improved according to the nature of being easilycharged with static electricity that the inorganic fine particles have.

The sheet manufacturing apparatus of the embodiment includes, in thesecond web forming unit 70, the mesh belt 72 and the suction mechanism76 that form the web W, and it is possible for the suction mechanism 76to be the suction unit that suctions the mixture discharged by thedeposition unit 60 via the mesh belt 72. By the suction unit performingsuction via the mesh belt, although the possibility of the compositedetaching from the fibers increases, according to the sheetmanufacturing apparatus of the embodiment, it is possible to suppressdetachment of the composite from the fibers regardless of whether asuction unit is included.

2. Sheet Manufacturing Method

The sheet manufacturing method of the embodiment includes a step ofmixing the fibers and the composite, in which the resin and theinorganic fine particles are integrated, in air, and a step ofdepositing, heating and forming a mixture in which the fibers and thecomposite are mixed. Because the fibers, the resin, the inorganic fineparticles, and the composite are the same as those described in theabove-described sheet manufacturing apparatus item, detailed descriptionthereof will not be provided.

The sheet manufacturing method of the embodiment may include at leastone step selected from a group composed of a step for cutting a pulpsheet or recycled paper as a raw material in air, a defibrating step ofdisentangling the raw material in air into a fibrous form, a classifyingstep of classifying, in air, impurities (toner or paper strengtheningagent) and fibers (short fibers) shortened by defibration from thedefibrated material that is defibrated, a screening step of screening,in air, long fibers and undefibrated pieces that are insufficientlydefibrated from the defibrated material, a dispersing step of causingthe mixture to descend while being dispersed in air, a forming step offorming the descended mixture in a web shape or the like while beingdeposited, a drying step of causing the sheet to be dried as necessary,a winding step of winding the formed sheet into a roll shape, a cuttingstep of cutting the formed sheet, and a packaging step of packaging themanufactured sheet. The details of these steps are the same as thosedescribed in the above-described sheet manufacturing apparatus, and thusdetailed description will not be repeated.

3. Sheet

The sheet S manufactured by the sheet manufacturing apparatus 100 or thesheet manufacturing method of the embodiment indicates a sheet in whichat least the above-described fibers are the raw material and formed intoa sheet form. However, there is no limitation to a sheet form, and theshape may be a board form, web form, or a shape having concavities andconvexities. The sheets in the specification can be classified intopaper and non-woven fabric. Paper includes forms in which pulp orrecycled paper as a raw material is formed in a sheet shape, andincludes recording paper for the purpose of writing or printing,wallpaper, packaging paper, colored paper, image paper, Kent paper andthe like. Non-woven fabric is a product thicker than paper or with lowstrength, and includes ordinary non-woven fabrics, fiber boards, tissuepapers, kitchen papers, cleaners, filters, liquid absorbing materials,sound absorbers, shock absorbers, mats, and the like.

In the case of a non-woven fabric, the gap between fibers is wide(density of the sheet is low). In contrast, the paper has a narrow gapbetween fibers (density of the sheet is high). Therefore, the sheet Smanufactured by the sheet manufacturing apparatus 100 or the sheetmanufacturing method of the embodiment being a paper is more able toremarkably express the action and function of suppressing detachment ofthe composite from the fibers, uniformity of strength when formed as asheet or the like.

4. Accommodation Container

The accommodation container of the embodiment is used while the fibersare mixed and accommodates the above-described composite in which theresin and the inorganic fine particles are integrated.

The composite of the embodiment is supplied to the mixing unit 50according to the opening and closing of a filter or valve. The compositeof the embodiment is supplied in a powdered state in appearance.Therefore, it is possible to configure the apparatus so that thecomposite is directly supplied to the mixing unit 50 through a pipe orthe like after being manufactured. However, according to theinstallation location of the apparatus, it is thought that the compositeis carried along a flow path as a commodity, and there are cases wheretransfer or storage is performed after the composite is manufactured.

The accommodation container of the embodiment includes an accommodationchamber that accommodates the composite, and it is possible for thecomposite to be accommodated in the accommodation chamber. That is, itis possible for the accommodation container of the embodiment to be acomposite cartridge, and it is possible to easily transport and storethe composite.

The shape of the accommodation container is not particularly limited,and it is possible for the shape to be made a cartridge shape suitableto the sheet manufacturing apparatus 100. It is possible to form theaccommodation container with an ordinary polymer material. Theaccommodation container may also be a box-like robust form, or may be afilm-(bag) like flexible form. It is preferable that the material thatconfigures the accommodation container is configured from a materialwith a high glass-transition temperature or melting point compared tothe material of the accommodated composite.

The accommodation chamber that accommodates the container is notparticularly limited as long as it is able accommodate and hold thecomposite. It is possible for the accommodation chamber to be formedfrom a film, a molded body or the like. In a case where theaccommodation chamber is formed by a film, the accommodation containermay be formed including a molded body (housing) so as to accommodate thefilm that forms the accommodation chamber. The accommodation chamber maybe formed by a comparatively robust molded body.

The film or molded body that forms the accommodation chamber may beconfigured from a polymer, a metal deposition film or the like, and mayhave a multilayer structure. In a case where the accommodation containeris formed by a plurality of members such as a film or molded body, fusedparts or bonded parts may be formed. In a case where the accommodatedcomposite (powder) is influenced, such as deterioration, due to contactwith the atmosphere, it is preferable that the film or molded body isformed from a material with little gas permeability. It is preferablethat the material of the part that contacts the accommodated compositefrom the materials of the film and molded body that configure theaccommodation chamber is stable with respect to the composite.

The shape and volume of the accommodation chamber is not particularlylimited. Although the composite is accommodated in the accommodationchamber, an inactive solid or gas may be accommodated in contrastthereto. The volume of the composite accommodated in the accommodationchamber is also not particularly limited.

The accommodation chamber may include a flow port that communicatesbetween the interior of the accommodation chamber and the exterior ofthe accommodation container, and is able to remove the composite to theoutside of the composite. The accommodation chamber may have anotherflow path other than the flow port formed therein. The other flow pathmay be configured by a release valve or the like. In a case of providingthe release valve in the accommodation chamber, although the position atwhich the release valve is arranged is not particularly limited, thereare cases where providing the release valve is preferable because thecomposite is not easily discharged when the pressure is released to theatmosphere in cases where pressure and the like is generated in theaccommodation chamber when arranged on the opposite side to thedirection in which gravity acts in the normal posture when transferred,transported, and used.

5. Other Provisions

Although the sheet manufacturing method and sheet manufacturing methodof the embodiment use no or only a small amount of water, it is possibleto manufacture the sheet while adding water, as appropriate, with theobject of adjusting the moisture or the like, through spraying or thelike as necessary.

It is preferable to use pure waters such as ion-exchange water,ultrafiltered water, reverse osmosis water, and distilled water orultrapure water as the water. In particular, because water in whichthese waters are subjected to sterilization treatment by irradiationwith ultraviolet rays or addition of hydrogen peroxide is able tosuppress the generation of mold and bacteria over a long period of time,such water is preferable.

In the specification, the phrasing “uniform” indicates, in a case ofuniform dispersion or mixing, the relative positions where one componentis present with respect to the other component are even in the entiresystem or are the same or substantially equal in each part of the systemto one another in a substance able to define a component with two typesor more or two phases or more. Uniformity of coloring or uniformity oftone indicates an even concentration without tinting of the color whenthe sheet is seen in plan view.

In the specification, phrasing such as “uniform”, “same”, “evenintervals” and the like are used to indicate that density, distance,measurement or the like are the same. Although it is desirable thatthese are equal, because being made completely equal is difficult, thewording includes being shifted by the cumulative errors or variationswithout the values being equal.

6. EXAMPLES

Below, although the present disclosure will be further described by theexamples shown, the invention is not limited to the examples below.

6.1. Preparation of Composite

(1) styrene-maleic acid resin (Tg: 74° C., molecular weight 6600): 1.5kg

(2) polyester resin (Tg: 56° C., molecular weight 10000): 8.0 kg

(3) copper phthalocyanine pigment (Pigment Green 36): 0.5 kg After theabove materials were mixed in the hopper, the materials were fed to atwin screw kneading extruder and melt-kneading was performed at 90° C.to 135° C. The material was extruded by dicing to form strands, and cutinto approximately 5 mm lengths to obtain tables.

After the tablets obtained above were subjected to processing for 30seconds in a high speed mill and the tablets were roughly crushed into agranular form, the material was fed to a jet mill to obtain a powderwith a particle diameter range of 1 μm to 40 μm.

Powdered resin particles (Al) configured from particles with avolumetric average particle diameter of 12 μm and a particle diameterrange of 5 μm to 23 μm were obtained from the obtained powder obtainedusing the jet mill in the classifying device.

6.2. Example 1

(1) resin particles (A1): 100 g

(2) inorganic fine particles (M1): 1.5 g By feeding the above materialsinto a tabletop blender, and agitating at a tip speed of 30 m/s for 80seconds, the surface of the resin particles (A1) is coated with theinorganic fine particles (M1). The presence of a coating was verified byobserving the particle surface with an SEM. Verification was alsoperformed according to changes in the angle of repose were alsoverified. This is determined from the angle of repose decreasing whenthe coating (covering by inorganic fine particles) is formed. Theinorganic fine particles (M1) use titanium dioxide in which thevolumetric primary particle diameter in which the surface is subjectedto hydrophobizing treatment with alkyl silane is 14 nm.

6.3. Example 2

Fine particles of silicon dioxide with a volumetric primary particlediameter of 12 nm in which the surface is modified by trimethyl silaneare the inorganic fine particles (M2). Other than using the inorganicfine particles (M2) instead of the inorganic fine particles (M1) used inExample 1, Example 2 is the same as Example 1.

6.4. Example 3

Fine particles of silicon dioxide with a volumetric primary particlediameter of 20 nm in which the surface is modified by trimethyl silaneare the inorganic fine particles (M3). Other than using the inorganicfine particles (M3) instead of the inorganic fine particles (M1) used inExample 1, Example 3 is the same as Example 1.

6.5. Example 4

Fine particles of silicon dioxide with a volumetric primary particlediameter of 20 nm in which the surface is modified by trimethyl silaneare the inorganic fine particles (M4). Other than using the inorganicfine particles (M4) instead of the inorganic fine particles (M1) used inExample 1, Example 4 is the same as Example 1.

6.6. Example 5

Resin particles (A1) without any coating on the surface were formed.

6.7. Measurement of Charging Amount

(1) Standard Carrier N-01 (available from the Imaging Society of Japan):4.85 g

(2) Powder of each example (composite or resin particles): 0.15 g

The above materials were fed to an acrylic container, the containerrotated for 180 seconds at 100 rpm with the container mounted to a ballmill table, and the carrier and particles (powder) were mixed. Theabsolute value [|μC/g|]of the average charging amount of mixture inwhich the powder and the carrier are mixed was obtained with a compactdraw-off charge measurement device (manufactured by TREK Japan KK, Model210 HS-2), and disclosed in Table 1.

6.8. Evaluation of Retention Rate of Particles to Fibers

(1) Nadelbaume Kraft Pulp (NBKP): 16 g

(2) Composite Particles (Examples 1 to 4) or resin particles (Example5): 4 g

(3) Particle Content Rate: 4 g/(16 g+4 g)=20% by weight The above masseswere weighed and introduced to a 520 mm×600 nm×0.030 mm transparentpolyethylene bag, air was blown in with an air gun, and pulp and thecomposite or resin particles were agitated by the airflow to mix amixture (powder of each example) of pulp and the composite or pulp andthe resin particles.

5.0 g of each powder of each example was extracted and gently spreadequally on a 140 mesh standard sieve with tweezers. Thereafter, thesieve was covered and set on a suction device on the upper side of thesieve. FIG. 3 shows a schematic view of the suction device 200. Thesuction device 200 used is a self composed device, and is formed from afunnel-type funnel portion 220 on which the sieve 210 is set, adischarge device 230, and a discharge filter 240 with the configurationsshown in FIG. 3. In the apparatus, in a case where a sieve 210 on whichnothing is mounted is provided, the discharge speed of the dischargedevice 230 is adjusted so that the air speed at the mesh surface of thesieve 210 becomes 25±1 m/s. As long as the wind speed conditions aresatisfied, the form of the device may not necessarily be as shown inFIG. 3. The value when the mass of each remaining mixed body aftersuction was performed for 30 seconds with the sieve 210 set on thesuction device 200 in a state where each mixed body is interposed by thesieve 210 is X(g).

Here, the particle retention rate RV (%) is derived according to theformula RV=(5×0.2−(5−X))/(5×0.2)×100=(X−4)×100. It is shown that thehigher the particle retention rate, the more of the mixed body is heldbetween the fibers of the pulp, and if the RV=100%, particles of themixed body do not pass through the sieve 210 due to suction, and it canbe said to be ideal. The particle retention rate of each example isdisclosed in Table 1.

Although the weight of the mixed body interposed with the sieve 210 ineach example is made 5.0 g, the mass may be regulated, as appropriate,from the testing efficiency. However, in each sieve 210 used inmeasurements, a volume of mixed body able to cover the entire surface ofthe sieve plane. In a case where a mass of mixed body that satisfiesthese conditions is selected, the value of RV obtained tends to notdepend on the mass of the mixed body.

TABLE 1 Particle Coating Type of Inorganic Fine Particle ExampleParticles and Volume Average Charging Amount Retention Rate No. ParticleDiameter Surface Modification [|μmC/g|] [%] 1 Titanium Dioxide ParticleTriisobutyl Silane 94 97 Diameter 14 nm 2 Silicon Dioxide ParticleTrimethyl Silane 88 95 Diameter 12 nm 3 Silicon Dioxide ParticleTrimethyl Silane 75 93 Diameter 20 nm 4 Silicon Dioxide ParticleTrimethyl Silane 41 79 Diameter 40 nm 5 Not Used — 25 59

6.9. Evaluation Result

The sample characteristics and particle retention rate for each exampleare summarized in Table 1.

As in the above Table 1, it is determined that the charging amount ofthe obtained powder is able to be controlled by changing the coatingstate due to the inorganic fine particles of the resin particles. It isunderstood that it is possible to control the particle retention ratewith respect to the pulp fibers by controlling the charging amount. Itis thought that as the charging amount of the particles (composite)increases, the particle retention rate tends to increase, and theparticle retention rate increasing is a state where the resin particlesof the composite are firmly attached to the pulp fibers (cellulose) andnot easily detached.

In light of Table 1, it is further found that since the particleretention rate becomes approximately 80% or more when the absolute valueof the average charging amount is 40 μC/g or more, a level that is notdamaged in sheet manufacturing in practice is attained. It is found thatwhen the absolute value of the average charging amount is 80 μC/g ormore the particle retention rate becomes 95% or more, and detachmentfrom the fibers of the resin particles (composite) becomes extremelylow, and is more favorable.

When the composite is a composite having a charging amount in the rangesas in Examples 1 to 4, the resin component is not easily detached fromthe fibers when manufacturing the sheet with a dry method, and, as aresult, a tough sheet can be manufactured according to the design.

The present disclosure is not limited to the embodiments describedabove, and further, various modifications thereof are possible. Forexample, the invention includes configurations which are substantiallythe same as the configurations described in the embodiments (forexample, configurations having the same function, method, and results,or configurations having the same purpose and effect). The inventionincludes configurations in which non-essential parts of theconfigurations described in the embodiments are replaced. The inventionincludes configurations exhibiting the same actions and effects as theconfigurations described in the embodiments or configurations capable ofachieving the same object. The invention includes configurations inwhich known techniques were added to the configurations described in theembodiments.

1-8. (canceled)
 9. A composite to be mixed with fibers for forming asheet by heat, the composite comprising: a resin particle for bondingthe fibers; and inorganic fine particles that coat at least a portion ofa surface of the resin particle.
 10. The composite according to claim 9,wherein the inorganic fine particles are attached to or bonded to thesurface of the resin particle.
 11. The composite according to claim 9,wherein the inorganic fine particles are encapsulated by the resinparticle.
 12. The composite according to claim 9, further comprising atleast one of a coloring agent and a flame retardant.
 13. The compositeaccording to claim 9, wherein an absolute value of an average chargingamount of the composite is 40 μC/g or higher.
 14. The compositeaccording to claim 9, wherein the volumetric average particle diameterof the resin particle is 25 μm or less.
 15. The composite according toclaim 9, wherein the volumetric average particle diameter of theinorganic fine particles is 40 nm or less.
 16. The composite accordingto claim 9, wherein the content of the inorganic fine particles in thecomposite is 0.1% by weight or more to less than 4% by weight.